Flexible ducting plays an important role in keeping air flowing safely and efficiently through all kinds of systems, from HVAC and dust extraction to fume ventilation and industrial processing. Whether it’s used in a workshop, manufacturing plant, or commercial building, flexible ducting helps manage air quality, reduce exposure to harmful particles and maintain comfortable, safe environments.
But like any essential part of a system, it’s not just about having ducting in place. The quality of the ducting, its installation, and maintenance can make a significant difference. Poor-quality materials or incorrect installation can lead to leaks, energy waste, safety hazards, or even costly repairs.
That’s where Searose Environmental can help. We supply and install high-quality flexible ducting and hose systems across a wide range of industries in Australia, including food processing, woodworking, construction, and metalworking. With decades of experience, we know the most common mistakes people make when it comes to flexible ducting — and more importantly, how to avoid them.
In this blog, we’ll explain what flexible ducting is, where it’s used, and the top five mistakes people make with flexible ducting. We’ll also provide guidance on how to avoid these mistakes for better performance, safety, and value.
What is flexible ducting?
Flexible ducting, also known as ‘flex duct’ or simply ‘flex’, is a type of ductwork made from materials like PVC, polyurethane, or metal-reinforced plastic. It’s designed to move air, fumes, dust, or materials through a system and is commonly used where space is limited or traditional rigid ducting can’t do the job.
Flexible ducting is popular because it’s easy to work with. It bends and curves around tight spots, making installation faster and simpler than rigid ductwork. It also comes in a range of materials, including heat-resistant, abrasion-resistant, and food-grade options, making it ideal for all kinds of projects. Many types are insulated to help maintain air temperature and prevent condensation.
While it’s often used in HVAC systems, flexible ducting is just as useful in dust extraction, fume control, and ventilation across industries like woodworking, metalwork, and food processing.
However, if it’s not installed correctly, its flexibility can become a drawback. Sharp bends, kinks or crushed sections can reduce airflow, cause leaks, and wear out the system more quickly.
What are the benefits of flexible ducting?
Easy to install
Because it bends and curves, flexible ducting can be fitted into tight or awkward spaces with minimal tools or effort. This makes it a great option for retrofit projects or complex layouts.
Cost-effective
Flexible ducting tends to be cheaper to buy and install than rigid ductwork. You also save on labour costs thanks to quicker installation times.
Space-saving
Its flexibility allows it to be routed around obstacles or in areas with limited clearance. It’s also perfect for compact industrial settings or unique building layouts.
Reduces noise
Flexible ducts absorb sound and vibration more effectively than rigid metal ducts, which helps reduce operational noise.
Energy efficient
If properly sealed and supported, insulated flex ducting can help maintain air temperature and reduce energy loss.
Tough and durable
Modern flexible ducting is built to last, with features like crush resistance, corrosion resistance, and leak prevention. It’s also easier to maintain and repair than many people think.
Read: What Are the Benefits of Flexible Ducting?
5 common flexible ducting mistakes and how to avoid them
Airflow restrictions
Too many tight bends, kinks, or long, unsupported runs can restrict airflow, forcing your system to work harder than necessary.
How to avoid it
Plan your layout to avoid sharp turns and excessive bends. Use gentle curves and secure the duct with proper supports to maintain a clear path for airflow.
Leaks at joints or connections
Improper sealing at joints or connections can lead to air loss, higher energy use, and even contamination of clean air.
How to avoid it
Use quality mastic sealant or high-grade duct tape to seal all joints. Regularly inspect connection points for wear or loosening over time.
Insulation issues
If insulation is crushed, damaged or missing, you risk condensation, energy loss, and even mould buildup.
How to avoid it
Make sure the duct is properly insulated and that the insulation stays intact and well-secured. If it’s damaged, replace it with high-quality foil-backed insulation.
Sagging or unsupported ducts
Without proper support, ducts can sag, compress, and restrict airflow, especially on long runs.
How to avoid it
Use straps, hangers, or supports every 1 to 1.2 metres to keep ducts lifted and free from compression. Avoid sharp supports that can damage the ducting over time.
Wear and tear
Over time, flexible ducting can develop small tears, punctures, or general degradation, particularly in demanding environments.
How to avoid it
Inspect your ducting regularly. Small holes can be patched, but significant damage often means replacement. Always use the right type of duct for the job — some materials are better suited for specific applications, such as heat resistance, resistance to abrasion, or resistance to certain particles.
How to prevent flexible ducting mistakes
Install it properly
Professional installation makes all the difference. A trained installer will seal joints, position ducts for maximum efficiency, and make sure it’s fully supported from the start.
Regular maintenance
Just like any other part of your system, flexible ducting needs regular checks. Look out for sagging, damage, or leaks, and clean ducts periodically to keep airflow moving freely.
Read: Industrial HVAC Maintenance: Everything You Need to Know
Choose quality products
Not all ducting is created equal. Cheap materials may save you money upfront, but they can cost you more in the long run. At Searose, we only stock high-quality, durable ducting that’s built for long-term performance.
Whether you’re upgrading your current system or setting up a new one, Searose Environmental is here to help. We offer a wide range of flexible ducting and hose solutions tailored to your specific application, from food-grade systems to heavy-duty industrial use. Get in touch with us and discover how we can help you.